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Help! Anyone rebuild a failed fuel level sending unit? 900

posted by  RepairmanJackal on  Wed Mar 9 04:16 CST 2005
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last visit: Tue Jun 10 09:52 CST 2014
[RELATED]

Thanks to some help from the FAQa and Spook, I've determined that my fuel gauge doesn't work because the fuel level sending unit is sending NO resistance reading to the gauge.

Considering the cost of a replacement, and lack of availabilty of replacements (they all seem to be for turbos), I've resigned myself to a painful rebuild/repair.

I have a couple of questions before I attempt this task:

(1) Are there any pictures (or line drawings) from a past rebuild?

(2) If the contacts are worn out, what is a good source for new contacts, and what are the dimensions needed? (I want to be ready for the repair before I take the unit out)

(3) I've seen several mentions of "corroded wires" at the sender unit, is it possible that the wires are simply broken inside the tank?

(4) I get absolutely NO ohms from the sender unit wiring, is that unusual for a failed unit? Could it indicate that busted wiring or something else on that end of the fuel gauge system?
--
Volvo #6: all wagons.... 1972 145S, 1976 245 DL, 1983 245 GL, 1986 740 GLE, 1990 740 GL, now a 1995 940...What's Next?






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